The harness manufacturing process is time-consuming, difficult and task oriented. Nevertheless, with the increasing demand for harness and cable assemblies, the manufacturing of these components is also expanding. That's because wire harness is one of the most indispensable electronic and electrical components in the modern world!

Step 1: Design

Whether the harness is hidden behind the glove box of the car or the back plate of the washing machine, the harness provides power and transmits information in a streamlined and unified way. In the research and development of electronic products, engineers must face and overcome electrical problems every day in order to successfully promote products to the market. An integral part of this challenge requires custom design of the electronic components of each product and the gradual completion of the assembled harness manufacturing process. This is also the stage where the engineer must select harness components and determine other use specifications.

Step 2: Prototype Design

If necessary, harness prototyping enables engineers or product designers to obtain a true version of the final product. They can then test the harness in their intended application before starting the first production run to ensure optimal performance.

Step 3: production and assembly

The manual assembly of the harness must meet the design specifications and maintain the high quality standard with the minimum error rate in the harness manufacturing. It is worth noting that in today's era, with the global expansion of automatic manufacturing in almost every field, the harness manufacturing process still depends on manual assembly to a large extent. Although some automation can be added to the process, the harness and cable assemblies must be manufactured manually because of the many complex and time-consuming steps involved in completing the process. Although building harnesses can be difficult and task oriented, manual production is still more cost-effective.

Another reason why manual production remains the main method of manufacturing harness and cable assemblies is that they must be customized for each application. Harnesses are very special components designed for specific large parts. They need to solve geometric and electrical problems in manufacturing products and provide solutions to specific problems inherent in the whole process. Geometrically, harnesses are designed to be installed in a specific space in or next to larger electronic components and cabling networks. The harness must also be grounded and protect the wires from potential internal and external damage associated with electrical problems, such as cross wires, chemicals or moisture.

Wire cutting

Broadly speaking, the first step in building a harness is to ensure that the wire is cut to the correct length, which is done by a wire cutter.

Stripping and joining

The next step requires that the end of the wire must be stripped to expose the core wire. This is done in order to connect the terminal or connector housing or module next.

Finally, use the workbench or assembly board to gather the wires into the harness to meet the design specifications.

Manual manufacturing of harness production is necessary for threading wires through sleeves and applying fabric tape where required, such as on branches of harnesses. The terminal needs to be crimped to the wire. If more than one wire needs to be connected to one terminal, it needs to be crimped several times. In addition, inserting one sleeve into another is done manually, so secure any strand with tape, clips or cable ties.

The manual production of wire rod processing machine does not exclude the use of automation and machinery in wire bundle manufacturing. The cutter is used to cut the wire evenly to the specified length, and the machine is used to crimp the terminal or insert the part of the wire with suitable terminal into the connector module. The soldering machine is necessary to seal the end of the wire, just like a tool to twist the wire.

Step 4: Test

After production, each individual harness must be tested for electrical safety according to any specification it may be subjected to in actual operation. This step is essential to ensure 100% reliable operation of the final product.

Harness manufacturing is a process. The design and assembly from drawing board to finished wire harness requires gradual planning and a large number of manual production. Each harness has a specific purpose and can be integrated into a larger electronic network, which really makes the harness indispensable in the modern world.